Interlaminar flocked laminate

ABSTRACT

An article of manufacture comprising a heat and pressure consolidated assembly comprising, in superimposed relationship, 
     1. a thermoset resin impregnated, decorative paper layer and 
     2. a thermoset resin impregnated paper sheet having 
     A. a dry adhesive coating positioned on one side thereof and 
     B. flocked fiber implanted in said adhesive in generally a perpendicular orientation to said sheet, 
     Is disclosed.

BACKGROUND OF THE INVENTION

In the manufacture of laminates, especially decorative laminates, it hasgenerally been necessary to somehow treat or condition the backmost sideof the laminate before it can be readily adhered to a substrate. Forexample, in the production of horizontal and vertical decorativesurfaces, decorative laminates of up to about 1/16 inch in thickness areadhesively bonded to substrates, usually flakeboard etc., by coating theside of the substrate to which the laminate is to be bonded, with a lowcost, water borne adhesive such as urea-formaldehyde or polyvinylacetate latex (white glue). In order to acheive effective andlong-lasting adherence of the laminate to the substrate, it has beennecessary to sand the backmost surface of the laminate because thissurface is normally smooth due to the use of a glassine separator sheetin the laminate manufacture. Attempts have been made to eliminate thesanding operation because of its expense and undesirable dust productionby attaching a polyvinyl acetate layer to the backmost side of thelaminate and then activating this layer with heat or a solvent beforeapplying it to the substrate, see U.S. Pat. No. 3,551,283 and No. Re.27644.

This method of circumventing the sanding operation has not proven to becommercially attractive and alternative means have been sought for someconsiderable time.

SUMMARY OF THE INVENTION

We have now discovered a laminate component which need not be sandedbefore it can be adhesively bonded to a substrate. The fact that nosanding is necessary results in a more economical laminate productionprocess because a plateless pack may be employed in the laminating pressand, once heat and pressure consolidated, the laminates of the pack maybe trimmed en mass rather than individually as is required when sandingof the back is necessary. Trimming the laminates in this manner, becausethey are relatively thin and brittle, causes less breakage of cornersetc. and consequently production is increased. Furthermore, theelmination of the sanding operation also eliminates the need to disposeof the sanding dust per se which, of course results in the saving ofboth time and money.

DESCRIPTION OF THE INVENTION INCLUDING PREFERRED EMBODIMENTS

As mentioned briefly above, we have now discovered a novel laminatecomponent which can be incorporated into a laminate and adhesivelybonded to a self-supporting substrate without the necessity of treatmentof the backmost side of the laminate.

This laminate component comprises

1. a thermosettoing resin impregated paper sheet,

2. a dry adhesive coating positioned on one side of said sheet, saidadhesive being substantially non-flowable in said dry state whensubjected to the conditions of heat and pressure laminate consolidation,and

3. flocked fibers implanted in said adhesive in generally aperpendicular orientation to said sheet.

This laminate component having one surface to which a flock has beenadhesively bonded and whose bulk has been impregnated with athermosetting resin is useful as the backmost layer on a decorativelaminate. After heat and pressure consolidating it together with theother laminate components, the resultant article may be bonded directlyto a substrate without standing.

While not wishing to be bound to any particular theory as to why theinstant laminate components function as they do, it is believed that theflock thereof simulates the condition which is achieved whenconventional decorative laminate backs are sanded. Microscopicexamination of a sanded laminate back shows that it contains a multitudeof fiber-like appendages. Some of these appear to be actual paper fiberswhich are lifted up from the paper surface by the sandpaper particleswhile others appear to be very fine ribbons of the resin impregnatedpaper cut by the sandpaper. They resemble wood shavings achieved whencutting lumber with a hand-held plane or coiled metl strips achievedwhen machining ductile metals. It appears that the presence of theseappendages is extremely important to the integrity of the adhesivejoints made on the finished article when such a laminate is bonded to atypical wood particleboard substrate. Where no appendages exist, theback surface of the laminate presents a smooth surface and when theinterface of this surface and the adhesive is placed under stress, suchas, for example, when the article shrinks during low humidityconditions, a crack initiates in the interface and runs along theinterface until the stress is relieved.

The surface presented to the bonding adhesive by the flocked surface ofthe laminate component of the instant invention is fibrous. The adhesivesurrounds each fiber, i.e., each fiber is implanted in the adhesivelayer. This results in a laminate-adhesive interface which is pierced bynumerous fibers since they are substantially perpendicular inorientation with respect to the plane of the interface. If a crackinitiates at this interface, it will not be able to propagate by runningalong the interface because as the crack front approaches a fiber, itwill encounter a region which is able to accept the stress, i.e., thefiber itself, and therefore will be stopped. The adhesive joint willhence remain unbroken.

Any resinous system known to be effective for the impregnation of papersheets to be used in the production of laminates may be used to producethe novel laminate components of the instant invention. The resins maybe those useful for the so-called "high pressure" or the so-called"low-pressure" laminate systems, i.e., those wherein the laminates areformed under heat and pressure consolidation whereon the pressureemployed is from about 1200 to about 1600 psi (high pressure) or fromabout 100 to about 400 psi (low pressure). These resins are all wellknown in the art and include those formed from the aminotriazines andaldehyde via condensation thereof. Suitable triazines include melamine,formoguanamine, acetoguanamine, benzoguanamine, ammeline, ammelide andthe like. Suitable aldehydes include formaldehyde, acetaldehyde,benzaldehyde, furfural, acrolein, butyraldehyde and the like.Phenol/aldehyde and urea/aldehyde condensation products may also be usedincluding those produced from urea per se, thiourea, methylene urea,ethylene urea, phenol per se, resorcinol, cresol, xylenols, t-butylcatechol, bisphenol A and the like. Further exemplary resinouscompositions of this type are disclosed in U.S. Pat. Nos. 2,197,357 and3,033,823, hereby incorporated herein by reference.

Further examples of impregating resins useful herein include resinousadmixtures of, for example, a nitrile rubber latex, a water-dispersiblemelamine/formaldehyde resin and a polyvinyl halide latex (U.S. Pat. No.3,798,117); mixtures of melamine/formaldehyde resins and thermoplasticacrylic copolymers (U.S. Pat. No. 3,736,220; 3,589,974; 3,547,769;3,218,225) which patents are also hereby incorporated herein byreference. Preferred are mixtures of a melamine/-formaldehydecondensation product and a cross-linkable copolymer of ethyl acrylateand acrylonitrile (80-20/20/80) wherein the mixture comprises from about50-95%, by weight, based on the total weight thereof, of themelamine/formaldehyde resin. The cross-linking sites on the copolymersare derived from hydroxyl or carboxy containing monomers copolymerizedtherewith in amounts of up to about 15%. Effective cross-linking sitescan also be created in the copolymer by chemical modification thereof.

Another example of useful impregnating resins are those based on diallylphthalate and disclosed in U.S. Pat. No. 3,049,458, hereby incorporatedherein by reference. These resins may be used as such or may becross-linked by any known means after impregnation. They are preferablyused with synthetic polymer papers, especially those produced frompolyacrylonitrile.

The paper sheet may comprise a sheet of any known material such as thosedisclosed in the above incorporated references. Such sheets includethose of kraft paper, α-cellulose paper, asbestos paper, regeneratedcellulose paper, paper produced from chopped rags, rayon, linen etc.,X-creped paper and the like.

The adhesive which is utilized to bond the flock to the impregnatedpaper sheet can comprise any adhesive material or composition which isnon-flowable in its dried state under the conditions of heat andpressure used to produce the laminate therefrom. The adhesive must actto bond the flock to the impregnated paper sheet and also, preferablyacts as a barrier which prevents the resin impregnated into the papersheet from surrounding the flock particles during pressing. We havefound that best results are achieved when the resin impregnated into thepaper sheet, the flocking adhesive, the flocked fiber and the adhesiveused to bond the laminate to the substrate are all "compatible". By"compatible" is meant that each of these components reacts substantiallythe same in the presence of a solvent. For example, if the solvent iswater, the resin imprenant should be water-soluble or water-dispersible.The flocking adhesive should be water-soluble or, at least, hydrophilic.The flock should also be hydrophilic and the substrate adhesive shouldbe water-borne. Since it is apparent that the flocked fiber must bebonded securely at one end to the laminate and at the other end to thesubstrate, it is clear that the fiber should be compatible with theadhesive used in the laminate component production and that used inbonding the laminate to the self-supporting substrate.

Any adhesive known to possess these qualities may be used herein. Wehave found that hydrolyzed polyvinyl alcohol functions successfully withwater-soluble impregnating resins and water-borne laminating adhesives.Cross-linking agents such as the alkoxylated alkyl melamines, e.g.hexakismethoxymethyl melamine alone or in the presence of an acidiccatalyst may also be added to the polyvinyl alcohol adhesive tocross-link it and render the ultimate laminate more water-resistant.Glyoxal reactants may also be used for this purpose. Phenolic resinadhesives, dialkylphthalate based adhesives and the like may also beused as the flocking adhesive.

The flocked fibers useful herein can be produced from any fiber formingmaterial. Those preferred are produced from cellulose, regeneratedcellulose, rayon, nylon, cotton, polyester and the like. As mentionedabove, the flock provides mechanical bond locking sites for the adhesiveused to bond the substrate to the laminate or laminate component. Theflock should not be too long because long sections of fiber tend to loopand become embedded in the flocking adhesive during heat and pressureconsolidation of the laminate components. Generally, we have found thatlengths of flock ranging from about 250μ to about 375μ are preferred;but those of from about 125μ to about 1250μ are satisfactory.

As mentioned above, the laminate components of the instant inventionfind use per se as cabinet liners, balance sheets etc. wherein they areadhered as such to the substrate with the application of pressure andusually heat. They also find use in the production of decorativelaminates which are used for such applications as kitchen cabinets,vertical furniture surfaces, wall panels etc. wherein the coveringprovides all the necessary protection and decorative qualities required.When used to produce such decorative laminates, whether high pressure orlow pressure, they are preferably topped with a conventional resinimpregnated decor or print sheet which provides the decorative patternof the final laminate. The flocked backed component and the decor sheetcan be laminated together under conventional conditions to provide athin, tough surfacing laminate, with or without a transparent overlaysheet on the decorative surface. Also, the flocked laminate component ofthis invention can provide the backmost sheet of a thicker decorativelaminate which may find usage as a desk top, counter top etc. by heatand pressure consolidating it together with a plurality, i.e., 2-9, ofresin impregnated core sheets. Typically, such core sheets are kraftpaper and the impregnated resin is a phenol/-formaldehyde resin.

The decorative papers from which the low-pressure and high-pressurelaminates are preferably produced are made from bleached wood pulp whichis high, at least about 60%, in alpha cellulose content. The papers arepigmented in a known manner to obtain the desired levels of color andopacity. They generally range in basis weight from about 50-90 poundsper 3,000 square foot ream. They should have controlled pH within about0.5 units of that of the impregnating resin in that variances in the pHof the paper and the resin can have adverse effects on the storage lifeof the treated paper and/or press cycle times when the laminate is beingproduced.

The decorative surface paper porosity (Gurley) is preferably controlledto 15-25 seconds per 100 cc of air to assure proper treating of thepaper with the resin and pressing of the laminate. A paper having toohigh a porosity will allow too much resin to penetrate and will resultin dry spots on the laminate produced therefrom. A paper with too low aporosity will not enable sufficient resin to penetrate and the excessiveresin on the surface will cause a mottled appearance and surface crazingand/or cracking of the resultant laminate.

impregnation of any of the paper sheets used in producing laminatecomponents and drying of said impregnated papers may be effected byconventional treaters and driers, i.e., 80°-125° C. for 3-50 minutes.Vits treaters have been found to be particularly useful in this regardand achieve a high resin pick-up and uniform surface coating withsufficient surface resin to achieve an adequate abrasion resistance. Theresin content of the impregnated papers generally ranges from about 30%to about 75%, by weight, based on the weight of the impregnated paper.Paper volatile levels are maintained at about 7% ± 0.5%. A balancebetween flow levels and treated weight of the treated paper ismaintained to assure proper abrasion levels without reducing crackand/or craze resistance. Treated paper is dried and stored flat in aconditioned storage area.

Core material, i.e., self-supporting substrates useful in producingdecorative low-pressure and high-pressure laminate include mediumdensity, mat-formed, wood particleboard and medium density, woodfiberboard. Useful core material, however, merely must enable theproduction of full-sized, smooth-faced, well bonded, crack and crazeresistant panels. Core materials should be stored for a sufficient timeat ambient conditions to achieve an equilibrium temperature and anequilibrium moisture content of 7% ± 2.0. Metal substrates may also beused.

The components claimed herein may be placed on both sides or only on oneside of the self-supporting substrate when low-pressure laminates arebeing produced. If the decorative sheet is placed only on one side ofthe substrate, it is preferred that a so-called balance sheet, i.e., amelamine/formaldehyde resin impregnated paper sheet, e.g., of kraft orother paper, sometimes called a cabinet liner, be placed on the otherside in order to prevent the resultant panel from warping duringpressing.

Various finishes may be applied to the decorative laminates. Forexample, the surface may be rendered glossy by using highly polishedplates, matte by interposing a texturizing release sheet between theplates and the decorative sheet or embossed by using etched plates.

The following examples are set forth for purposes of illustration onlyand are not to be construed as limitations on the present inventionexcept as set forth in the appended claims. All parts and percentagesare by weight unless otherwise specified.

EXAMPLE 1

To a suitable vessel containing 150.0 parts of a solution comprising55.0 parts of water, 12.0 parts of isopropanol and 33 parts of amelamine/formaldehyde resin (M/F ratio of 1:2) are added 100.0 parts ofan emulsion comprising 50.0 parts of water and 50.0 parts of an ethylacrylate-acrylonitrile copolymer containing reactive OH groups (GoodrichCo. Hycar® 2600x138). The result is an overall composition is then usedto impregante wet-strength kraft paper having a basis weight of about115 pounds per 3000 square foot ream, using a conventional Egan papertreating machine equipped with metering rolls. The gap of the meteringrolls, temperature and air flow in the drying ovens are adjusted untilthe paper has picked up about 37% solids with a 7% volatile content. Thedried paper is rolled up into a smooth even roll for subsequent use.

The roll is then remounted on the infeed end of the same treatingmachine and coated by a knife coater on its upper surface with a 10%solution of hot water-soluble, medium viscosity, substantially fullyhydrolyzed polyvinyl alcohol. The coating is 0.004 inch thick in the wetstate. When it is dried, it yields 0.7 gram/ft². While still wet, randomcut cellulose flock fiber (a pulverized bleached sulfite softwood pulpwith a mesh size of 200), 10-15 mils in length, is sprinkled on top ofthe wet coating by means of a hopper. The entire assembly is thenvibrated by means of a beater bar so as to orient the flockperpendicular to the paper and implant the fibers into the coating. Theexcess flock is removed by vacuum. A 1.4 gram/ft². dry flock pick-up isachieved. The resultant flocked paper is then dried to a 3% volatilecontent in a conventional, hot air conveyorized oven at about 250° F.,at a 1minute residence time and cut to size. The result is thermosettingresin impregnated paper sheets each with a dry adhesive coating on oneside thereof and having flocked fibers implanted in said adhesive inperpendicular orientation to said sheets. The sheets are now ready to beused as a laminate component in the production of high or low pressurelaminates.

HIGH-PRESSURE LAMINATE

A sheet, produced as above, is then arranged in a press assembly so thatthe flocked surface thereof will become the rear face of the finallaminate. The assembly is prepared by laying the flocked sheet atop a 1mil polypropylene release sheet with the flocked surface adjacent thepolypropylene. Atop this structure is laid printed decor sheet preparedfrom a printed 65 lb./3000 ft.² pigmented α-cellulose paper which hasbeen impregnated with the same melamine-acrylic composition set forthabove and dried. A two-sided glassine release sheet is placed upon thedecor sheet and the build-up is then repeated in reverse order untilanother polypropylene sheet is reached. The procedure is continued untilforty assemblies are produced. Kraft paper "cushions" are placed outsidethe top and bottom of the resultant "press pack" and finally, 3/8 inchsteel plates are used as "outside irons". The resultant assembly iscalled a "plateless pack" or a "veneer pack". It is 4 feet wide and 8feet long and is placed in a high pressure laminating press. The pack isheat and pressure consolidated at 1400 psi and 150° C. for 5-6 minutes.The pack is then cooled to room temperature, removed from the press andtrimmed at both ends and edges with an overhead travel saw. Theindividual laminates are separated from one another at the polypropyleneand glassine interfaces.

Upon removal from the press, the flocked fibers are compacted and forcedinto a position parallel to the plane of the laminate. Upon wetting withwater or upon the addition of an adhesive in an aqueous solution, thefibers immediately return to a position substantially perpendicular tothe laminate plane.

A. One of the recovered laminates is bonded to both planar faces of amedium density particleboard slab, 3/4 inch thick and 4 feet×8 feet inwidth and length, respectively, using a polyvinylacetate emulsionadhesive, commonly called white glue. The glue has a spread rate of19/grams/ft.² and the layers are held together at 40 psi for 30 minutes.The resultant structure is allowed to remain at ambient conditions forone week. The rearmost, flocked surfaces of the laminates are adjacentthe white glue line and the decorative surfaces thereof are visible.

Small 15 inch by 15 inch sections are cut from the structure and placedin a cabinet at 110° F., 10% R.H. and observed weekly for signs ofseparation of the laminate from the substrate. No failure is detectedafter 15 weeks.

B. A second laminate is bonded to both faces of a 4 feet×8 feet, 3/4inch exterior grade plywood substrate as in Section A, above, by meansof a commerically available, highly water-resistant, neoprene contactachesive commonly employed for the purpose. The resultant structure isallowed to equilibrate at ambient conditions for seven days. Specimens 2inches×3 inches are then cut from the structures and small screw eyesare attached to the center of one of the 2 inch ends of the plywoodcore. The other end is fitted with a lead weight so that the entirespecimen would sink when suspended on the screw eye and lowered intowater. The specimens are mounted on hooks above a water bath at 150° F.which is automatically activated to immerse them for 15 minutes and thenwithdraw them to a position about one inch above the bath for 45minutes. The cycle is repeated until failure of the polyvinyl alcoholbond between the flock fiber and the laminate. The specimens failedafter 27 cycles indicating that the polyvinyl alchol used to bond theflock to the paper layer is not sufficiently water resistant to permitusage of the structure under constantly moist conditions, such as in ashower stall and on a kitchen drain board.

C. One-foot square sections are cut from one of the above-producedlaminates and bonded onto 3/4 inch, 11 inches×11 inches medium densityparticleboard sections so as to have a 1/2 inch border of the laminateoverhanging the particleboard. The same "white glue" as described aboveis used. The samples are allowed to remain at ambient conditions for 24hours. In order to test the bond between the board and the laminate, asaw cut is made, through the laminate only, at a 45° angle to andintersecting the edge at 3 inches from each corner. By means of afixture, the structure is then pushed upward by means of its overhangingborder in such a way as to place the adhesive joint in tension and toseparate the laminate from the particleboard. Since the thin laminatelacks sufficient tensile strength to cause the particleboard to fail,each triangular section at each corner is reinforced by bonding to itsupper surface a section of standard 1/16 inch decorative laminate. Oneof each of the corners is stripped apart after 24, 48, 72 and 96 hoursfollowing the bonding operation. When the laminate is forced away fromthe particleboard, substantial amounts of wood particles are torn out,thereby showing that the adhesive joint strength exceeds the internalstrength of the particleboard itself.

LOW-PRESSURE LAMINATE

The impregnation procedure set forth above is again repeated except thatthe kraft sheet is replaced by a printed 65 lb./3000 ft.² pigmentedα-cellulose decor paper which has a wood grain pattern printed on oneside thereof. The decor paper is impregnated with the samemelamine-acrylic impregnating resin composition, dried, coated withhydrolyzed polyvinyl alcohol adhesive and flocked on the side oppositethe decorative pattern.

The flocked sheet is placed upon a section of 3/4 inch thickparticleboard of medium density and placed in a low-pressure panel pressutilzing a suitable release sheet on top of the decor sheet. Thecomposite is laminated at 410 psi and 140° C. for 1-2 minutes. Nofailure of the bond is observed when the resultant panel is tested at110° F. and 10% R.H. after 15 weeks, as above.

EXAMPLE 2

The procedure of Example 1 is again followed except that the polyvinylalcohol adhesive is modified by the addition of across-linker/insolubilizer thereto. To each 85.0 parts of the adhesiveare added 15.0 parts of hexakis methoxymethyl melamine and 0.3 part ofp-toluenesulfonic acid to achieve the result. Upon subjection of theresultant structure to the repeated immersion test, 72 cycles arereached without deterioration of the adhesive bond.

EXAMPLE 3

Again following the procedure of Example 1 except that the polyvinylalcohol adhesive is modified by adding 10.0 parts of glyoxal to every90.0 parts of adhesive, the resultant structure withstands 72 immersioncycles without failure.

EXAMPLE 4

The procedure of Example 1 is followed except that the high pressurelaminate build-up comprises, in superimposed relationship, 1 sheet offlocked, impregnated kraft paper, 7 sheets of impregnated kraft papercore, 1 sheet of impregnated α-cellulose decor paper and 1 sheet ofimpregnated, transparent overlay paper. These build-ups are repeatedwith a 1/8 inch polished steel plate between each one until a completepress pack is produced. After heat and pressure consolidation, theresultant laminates are recovered. Each laminate has a flocked backmostside which shows bonding characteristics similar to the laminates ofExample 1 when subjected to the tests described therein.

EXAMPLE 5

The procedure of Example 1 is followed except that a standardlow-pressure melamine/formaldehyde resin is employed to impregnate thelaminate component sheets. The mol ratio of melamine to formaldehyde is1.0 : 1.7. Similar results are again achieved.

EXAMPLE 6

The operations of Example 1 are again followed except that the kraftpaper is impregnated with a conventional phenolic laminating varnish toa resin content of 30%, a volatile content of 8% and a minimum flow of5%. The so-impregnated paper is coated on one side with a 30% aqueoussolution of a water-soluble phenolic resin which is thickened by theaddition of 1% β-hydroxyethyl cellulose (Natrosol 250®; Viscosity TypeH; 1% NaOH; Hercules Chem. Co.). The thickened resin solution is appliedat a wet thickness of about 1 mil and yields a dry coated equivalent of0.7 grams/ft.². A rayon flock of random grey color and 30-200 mesh issprinkled onto the wet phenolic coating and the resultant sheet ispassed through a conveyor oven for 10 minutes at 240° F. to dry and curethe phenolic used to bond the flock but to leave the impregnatedphenolic within the sheet essentially unchanged.

The resultant flocked sheet is then used as the rearmost ply of aconventional high pressure laminate. To produce the laminate, 6 plies ofa 115 pound kraft paper, impregnated with phenolic resin in a typicalmanner and dried, are positioned above the flocked kraft with theunflocked side adjacent the six kraft plies. Conventionalmelamine/-formaldehyde resin impregnated decor and overlay sheets arethen placed atop the 6 plies of kraft. The topmost overlay sheet iscovered with a stainless steel press plate and a 1 mil film ofpolypropylene is placed adjacent the flocked side of the lowermost kraftsheet. This assembly is repeated in a face-to-back arrangement until 12laminate packs are assembled. They are then consolidated under the usualconditions of heat and pressure. Upon cooling and disassembly, thelaminates are ready for adhesive bonding to any desired substratewithout the need for sanding the back, polishing the face or otherfinishing operation except trimming. When bonded to particleboard as inExample 1, the finished structures resist exposure in the low humiditycabinet, withstand 72 immersion cycles and exhibit wood particlefailure.

EXAMPLE 7

A paper composed of about 80% of a fibrillated acrylic fiber (see U.S.Pat. No. 3,264,170), containing about 20.0% of titanium dioxide andhaving a basis weight of 90 lbs./3000 ft.² ream is gravure printed witha woodgrain pattern.

The resultant printed paper is passed into a bath of a commerciallyavailable solution comprising 96.0 parts of a dialkylphthalateprepolymer and 4.0 parts of diallylphthalate monomer, 5.0 parts ofdicumyl peroxide in 68.0 parts of methyl ethyl ketone and 17.0 parts oftoluene. The printed surface is allowed to take up and return as muchresin as it can but the back surface is wiped of excess resin with ametal rod. The paper is dried. Analysis shows a resin pick-up of 50% ofthe total weight, i.e., about 13.5 grams of dry resin per square foot.The printed surface retains about 8.0 grams and the body of the paperabout 5.5 grams. Essentially no resin is retained on the back surface.

A 120 lb./3000 ft.² fibrillated acrylic paper, as above but free ofpigmentation, is coated with a diallylphthalate polymer solution similarto that disclosed above except that the solvents are each reduced to onethird of the amount tated. The coating rate is such that 2.0 grams ofresin solids is deposited per square foot of paper. While still wet, thecoating is sprinkled with polyester fiber flock, 100 mesh, of randomgrey color. The wet flock add-on is 1.4 grams/ft.². The flocked paper ispassed through a conveyorized hot air oven at 280° F. at a 10 minuteresidence time, whereby the resin adhesive binder is completelycross-linked. The roll is cooled and then mounted on a reverse rollcoater and the same diallyl phthalate resin solution as first mentionedabove is applied to the unflocked surface. The resin pick-up is adjustedto add 4.5 grams/ft.² and the paper is dried.

A 4 feet×8 feet sheet of the unflocked decor paper is placed adjacent astainless steel press plate with its decorative side against the plate.A 4 feet×8 feet sheet of the flocked paper with its unflocked surfaceadjacent the decor paper is then placed on top of the decor sheet. A 1mil sheet of polypropylene is used as a separator and the entireassembly is repeated in reverse. Six more pairs of such sheets arearranged in back-to-back relationship with faces separated by additionalpolished plates. The entire press mass is then consolidated under heatand pressure.

After cooling, the laminates are separated and trimmed. By means of aconventional, commercially available chloroprene solution "contact bond"adhesive, a laminate is bonded to a 1/16 inch thick aluminum plate whichhas been carefully cleaned and degreased. A similar structure isprepared using a 1/16 inch thick cold rolled steel plate. In bothinstances, the flocked side of the laminate is in contact with the metalsurface. The structures are aged 7 days at ambient temperature. Samplesare cut from the resultant structures and submitted to the repeatedimmersion test of Example 1. After 72 cycles, no evidence of separationcan be detected.

EXAMPLE 8

The procedure of Example 1 is again followed except that the resinousmaterial impregnated into the kraft paper and decorative sheet is acommercially available polyester resin and said adhesive is a polyesterresin. Again, an excellent high pressure laminate is produced.

EXAMPLES 9-11

The procedure of Example 2 is again follwed except that the flock fiberis (9) a polyester, (10) a nylon and (11) a cellulose acetate. In eachinstance, excellent bonding is achieved when the resultant laminate isadhered to a particleboard substrate.

We claim:
 1. An article of manufacture comprising a heat and pressureconsolidated assembly comprising, in superimposed relationship,1. athermoset resin impregnated, decorative paper layer and
 2. a thermosetresin impregnated paper sheet havinga. a dry adhesive coating positionedon the side thereof opposite said paper layer and b. flocked fibersimplanted in said adhesive in generally a perpendicular orientation tosaid sheet, said adhesive being substantially non-flowable in the drystate when subjected to the heat and pressure of high or low pressuredecorative laminating.
 2. An article according to claim 1 wherein aplurality of thermoset resin impregnated core sheets are positionedbetween said (1) and said (2).
 3. An article according to claim 2wherein a thermoset resin impregnated overlay sheet is positioned atopsaid decorative paper layer.
 4. An article according to claim 3 whereinsaid assembly is adhesively bonded to a self-supporting substrate, saidflocked fibers being positioned adjaced said substrate.
 5. An articleaccording to claim 2 wherein said assembly is adhesively bonded to aself-supporting substrate, said flocked fibers being positioned adjacentsaid substrate.
 6. An article according to claim 1 wherein a thermosetresin impregnated overlay sheet is positioned atop said decorative paperlayer.
 7. An article according to claim 6 wherein said assembly isadhesively bonded to a self-supporting substrate, said flocked fibersbeing positioned adjacent said substrate.
 8. An article according toclaim 1 wherein said assembly is adhesively bonded to a self-supportingsubstrate, said flocked fibers being positioned adjacent said substrate.9. A method for the production of the article of claim 1 which comprisesheat and pressure consolidating, in a superimposed relationship, anassembly comprising:1. a dry thermosetting resin impregnated decorativepaper layer and
 2. a dry thermosetting resin impegnated paper sheethavinga. a dry adhesive coating positioned on the side thereof oppositesaid paper layer and b. flocked fibers implanted in said adhesive ingenerally a perpendicular orientation to said sheetsaid adhesive beingsubstantially non-flowable in the dry state when subjected to the heatand pressure of high or low pressure decorative laminating.